Method for producing an elastic body with protective layer

ABSTRACT

Hospital mattresses are generally made of foam plastic having predominantly open cell cores and are in the form of a parallel-epipedic block which is provided with a protective layer consisting of a plastic film which is easy to clean so that injurious substances and bacteria can be removed. Such mattresses have the drawback, however, that when used they produce sounds which are disturbing. These sounds are eliminated in accordance with the present invention by arranging a layer of fabric between the outer surface of the foam plastic block and the protective layer.

This application is a division of application Ser. No. 391,688, filed June 24, 1982 (now U.S. Pat. No. 4,440,817).

The present invention relates to an elastic body which on its outer surface is entirely or partially provided with a protective layer. The body is generally made of a plastic which has been allowed to foam or expand. The body is thus composed of a number of cells, each enclosing a volume. Said cells are punctured to allow air to flow in and out through the cells. Puncturing of the cells is obtained by heat-treating the body. Such a body is provided entirely or partially with a film which is either placed over the body or secured through the body in one way or another. Adhesive or other known methods can be used to effect the attachment. One method is to heat the outer surface of the body so that it becomes tacky and the film applied thereon adheres to it. The purpose of the film is not to allow moisture through and it should also be of a type which will allow substances, bacteria and other particles which may adhere to the protective layer, to be easily removed with the help of a suitable cleaning agent. In certain cases treatment in an autoclave may even be advisable. Many applications are feasible for a body such as that described above which is coated with a protective layer. One application is as a bed mattress, in which case the body is generally parallel-epipedic in shape. The upper and lower surfaces and the longitudinal side surfaces of the mattress are coated with said protective layer. The transverse side surface, however, have no protective layer. This is to permit the passage of air to the cells in the mattress. The coated surfaces of such a parallel-epipedic body are generally somewhat rough and the layer applied is therefore not flat. This allows air to circulate between the upper surface and the user of the mattress. The movements of the user of such a mattress cause a creaking noise which is disturbing if the user is not alone.

The object of the present invention is to eliminate the above-mentioned disturbing sounds. This is achieved by placing a fabric layer between the body and said protective layer. The fabric may be attached both to the protective layer and to the body itself.

A suitable material for the fabric is nylon charmeuse. This may have a weight of 63 gram/m².

A suitable material for the mattress body itself is polyether. If polyether is used this should have a weight of 30 kg/m³. Highly elastic cold foam consisting of cold-foamed polyether may also be used. Its weight should be 37 kg per m³.

The present invention will be described more fully with reference to the accompanying two drawings in which the figures show a mattress in perspective at various stages of manufacture.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a mattress core between fabric layers.

FIG. 2 shows fabric layers covering the longitudinal sides of the core and attached or about to be attached thereto by a longitudinal strip disposed between the same.

FIGS. 3 and 4 show outer plastic layers placed over the fabric layers.

FIG. 5 shows the integrated elastic body of the invention.

In the drawings 1 is a mattress consisting of a parallel-epipedic core 15 of a plastic which has been allowed to expand to form a foam consisting of a number of cells, each enclosing a space. The cells have been penetrated by means of heat-treatment during production so that air can pass through them. A suitable material for the core is a material as above, which is also described in Table I.

                                      TABLE I                                      __________________________________________________________________________     Quality                       HE37                                             Color                         White                                            Standard Width                2000 mm                                          Total Height                  860 mm +/- 3%                                    Shoulder Height               700 mm +/- 3%                                    Bulk Density                  Gr. pr. kg/M.sup.3 +/- 4%                                                      38                                               ISO 1855/SIS 169209/DIN 53420 Net pr. kg/m.sup.3 +/- 4%                                                      36                                               Hardness Index                150 N +/- 4%                                     (50 mm) ISO 2439/SIS 169212/DIN 53576                                          Dynamic Fatigue               30 N                                             Height Loss ISO 3385/SIS 169212/DIN 53574                                                                    1.5%                                             Elongation                    220%                                             ISO 1798/SIS 169211/DIN 53571 Elongation at Break                                                            110 .sup.kPa                                     Deformation                   2.0%                                             ISO 1856/SIS 169213/DIN 53572                                                  Elasticity                    58%                                              SIS 169217                                                                     Impact Strength               3.6 .sup.kPa +/- 6%                              SO 3386/DIN 53577                                                              Field of Application                                                           Cushions, Office and Dining-room Furniture,                                    Mattresses                                                                     Comments                                                                       Fulfills requirements for Bulletin 117 sec. A & D                              STATE OF CALIFORNIA.                                                           Quality                       F30                                              Color                         Grey                                             Standard Width                2000 mm                                          Total Height                  1040 mm +/- 3%                                   Shoulder Height               880 mm +/- 3%                                    Bulk Density                  Gr. pr. kg/m.sup.3 +/- 5%                                                      29                                               ISO 1855/SIS 169209/DIN 53420 Net pr. kg/m.sup.3 +/- 5%                                                      27                                               Hardness Index                150 N +/= 4%                                     (50 mm) ISO 2439/SIS 169212/DIN 53576                                          Dynamic Fatigue               50 N                                             ISO 3385/SIS 169214/DIN 53574 Height Loss                                                                    3.0%                                             Elongation                    240%                                             ISO 1798/SIS 169211/DIN 53571 Elongation at                                                                  100 .sup.kPa                                     break                                                                          Deformation                   4.0%                                             ISO 1856/SIS 169213/DIN 53572                                                  Elasticity                    46%                                              SIS 169217                                                                     Impact Strength               3.3 .sup.kPa +/- 6%                              ISO 3386/DIN 53577                                                             Field of Application          LAMINATION                                       Comments                                                                       Fulfills requirements for FMVSS 302/1972 pt. 4.3 - laminatable                 __________________________________________________________________________

The mattress core has an upper part 2 and a lower part 3, two longitudinal sides 6 and 7 and two short sides 4 and 5. Two fabric halves are placed over the upper part 2, lower part 3 and longitudinal sides 6 and 7 so that said surfaces are completely covered by the two fabric halves. The opposite edges of the two fabric halves meet along the longitudinal sides 6 and 7. The fabric is preferably nylon charmeuse but other types of fabric may of course be used. Nylon charmeuse is described in Table II.

                  TABLE II                                                         ______________________________________                                         Woven Fabric Type Polyamide                                                    Warp-knitted product with binding LT 1 10-34 L2 01.10                          Manufactured from 44 D-Tex Polyamide, gauge 15.16/mm,                          giving a weight of 63 gram/m.sup.2.                                            ______________________________________                                    

The fabric may be secured to the mattress core, the latter having been heated to provide a tacky surface. The pieces of fabric covering the longitudinal sides 6 and 7 may be attached thereto by strips provided with attachment means on both sides. One such strip is shown in the drawings on the longitudinal side 6. This strip is designated 8 as shown in FIG. 2. The strip on the longitudinal side 7 is identical to the strip 8. A protective layer consisting of two halves 12 and 13 is placed over the fabric layers 9 and 10. The layers 12 and 13 consist of a plastic which is non-permeable and have a surface allowing bacteria, substances and other undesirable particles to be easily removed and which will also stand treatment in an autoclave. The plastic can be secured to the fabric-covered core by heating the core, whereupon the surface becomes tacky and this tackiness can penetrate through the fabric. Should this not be so, an adhesive or a foil provided on both sides with adhesive is applied between the fabric and the protective layer. The edges of the parts 12 and 13 of the protective layer are substantially in contact with each other along the longitudinal sides 6 and 7. Said parts can be caused to adhere by heating the mattress core or by using an attachment strip coated on both sides with adhesive and arranged between the fabric layers 9 and 10 and the protective layers 12 and 13. In the drawings such an attachment strip is only visible on the longitudinal side 6 where it is designated 11. The two joints formed by the parts 12 and 13 of the protective layer on the longitudinal sides 6 and 7 are covered by a covering strip, denoted 14 on the longitudinal side 6 as shown in FIG. 3. A suitable plastic for the protective layer is highly elastic polymer film. The plastic is described in Table III.

                                      TABLE III                                    __________________________________________________________________________     Physical properties                                                                                 Standard   TF-310 312.330-800                                                                            TF-410                          Test                 ASTM       Polyester      Polyether                       __________________________________________________________________________                                     1 Mll   3-5 Mll                                                                               1 Mll   3-5 Mll                 Specific Gravity     D-792  1.22                                                                               1.22    1.14   1.14                            Hardness Shore, A    D-2240 93(50D)                                                                            93(50D) 82     82                              Stress-Strain        D-883                                                     Ultimate Strength psi (MPA) MD* 9000(62.1)                                                                             8500(58.7)                                                                            6000(41.4)                                                                             6500(44.8)                                          TD* 5000(34.5)                                                                             8100(55.9)                                                                            3000(20.7)                                                                             5200(35.9)              100% Modulus, psi (MPA)     MD  3000(20.7)                                                                             1600(11.4)                                                                            1700(11.7)                                                                             800(5.5)                                            TD  1100(7.6)                                                                              1600(11.0)                                                                            530(3.7)                                                                               660(4.6)                300% Modulus, psi (MPA)     MD          4900(33.8)     1500(10.3)                                          TD          4800(33.1)     1100(7.6)               Elongation at Break, %      MD  200     410    350     570                                                 TD  400     410    650     630                     Tear Initiation, Graves, lb/ln (kg/cm)                                                              D-1004 MD  250(44.8)                                                                              500(107.4)                                                                            250(44.8)                                                                              430(77.0)                                           TD  500(89.5)                                                                              560(100.2)                                                                            380(68.0)                                                                              420(75.2)               Tear Propagation, lb/in (kg/cm)                                                                     D-1938 MD  250(46.5)                                                                              500(89.5)                                                                             260(46.5)                                                                              212(37.9)                                           TD  400(71.6)                                                                              560(100.2)                                                                            250(44.8)                                                                              272(48.7)               Moisture Vapor Transmission,                                                                        E-95-E 46  23      76     43                              gm/24 hr/100 sq. in.                                                           Abrasion Resistance, Taber CS-17                                                                               3       3      8                               5000 Cycles; 1,000 gm load; 75 mll             (1000 cycles)                   sample; mg lost Taber                                                          Impact Strength lb/in (kg/cm)                                                                       D-1709     400(71.7)                                                                              400(71.7)                                                                              390(69.9)                      Permeation Properties                                                          Gas transmission rate,                                                                              D-1434                                                    cc/24 hr/100 sq. in.                                                           Oxygen                          75      72     1000    542                     Nitrogen                        45      18     450     151                     Carbon Dioxide                  450     729    4300    6902                    Air                             55      28     NA      214                     Hellum                          NA      349    NA      1188                    MVT gm/mil/24 hr/100 sq. in.                                                                        E-96-E     8.6            1.86                            Thermal Properties (.075 sample)                                                                    D-746      -80(-62)       -100(-73)                       Solenold Brittle pt, °F. (°C.)                                   Masland Cold Crack, °F. (°C.)                                                         D-1790     -100(-73)      -100(-73)                       Gehman Stiffness Modulus,                                                                           D-1053                                                    psi(mpa)                                                                       @ Room Temp.                    1700(11.7)     570(4.1)                        @ 32° F. (0° C.)  2800(19.3)     750(5.2)                        @ 0° F. (-17.8° C.)                                                                              17500(120.7)   1000(6.9)                       @ -40° F. (-40° C.)                                                                              --             5900(40.7)                      Heat Seal Range                                                                °F.                      350-400        350-400                         °C.                      176-204        176-204                         __________________________________________________________________________      NA  Data not available                                                         *MD  Machine Direction.                                                        TD  Transverse Direction                                                 

    Immersion data                                                                 28 days @ 23° C. (73° F.) 5 mil film                                           Ultimate Tensile                                                                        Tensile Change                                                                         Ultimate Elong.                                                                        Elong Change                                                                           Volume Change                                                                          Weight Change           Test-         psi      (%)     (%)     (%)     (%)     (%)                     Base Material-                                                                               Ester                                                                               Ether                                                                              Ester                                                                              Ether                                                                              Ester                                                                              Ether                                                                              Ester                                                                              Ether                                                                              Ester                                                                              Ether                                                                              Ester                                                                              Ether               __________________________________________________________________________     Original      8500 5400                                                                               --  --  410 570 --  --  --  --  --  --                  ASTM Fuel A   7900 6500                                                                               -71  0  405 610  -1.2                                                                              +7.0                                                                               +1.7                                                                                +4.7                                                                               -0.1                                                                               +2.7               ASTM Fuel B   6200 4300                                                                               -27 -34 460 150 +12 +7.0                                                                               +8.7                                                                               +18  +8.3                                                                              +16                 ASTM Fuel C   7000 3800                                                                               -17 -42 510 590 +24 +3.5                                                                               +10 +34 +9  +30                 ASTM Oil Type 1                                                                              8100 NA  -6  NA  380 NA  -7  NA  +13 NA  +                                                                                  --5                 ASTM Oil Type 2                                                                              6700 6850                                                                               -21  +4.6                                                                              390 590  -4.9                                                                              +3.5                                                                               +0.3                                                                                +5.0                                                                              +.4  + 4.5              ASTM Oil Type 3                                                                              7400 3900                                                                               -13 -40 430 540  +4.9                                                                              -5.3                                                                               +3.2                                                                               +11  +2.4                                                                              +10                 Perchloroethylene                                                                            6500 3000                                                                               -24 -54 420 510 +15  -10.5                                                                             +20 +73 +22 +94                 Trichloroethylene                                                                            4800 2000                                                                               -44 -69 460 420 +12 -26 +54  +242                                                                              +51  +270               Benzene       5500 3300                                                                               -35 -49 500 670 +22 +17 +38  +108                                                                              +30 -95                 MEK           3600 *   -58 *   550 *   +34 *   *   +30 *   +27                 Isopropyl Alcohol                                                                            5300  300                                                                               -38 -95 510 670 +24 +17 +11 +34 +9  +26                 Saturated NaCl                                                                               7500 5300                                                                               -12 -18 410 560  0  -1.8                                                                               -0.7                                                                               NA   -0.6                                                                              --                  Ethylene Glycol                                                                              6800 5650                                                                               -20 -13 420 650  +2.4                                                                              +14 +4  +4  +4  +4                  20% NaOH      *    4800                                                                               *   -26 *   620 *   +8.8                                                                               -27 +5  -27 +6                  20% H.sub.2 50.sub.4                                                                         6600 2500                                                                               -22 -26 465 450 13.4                                                                               -2.1                                                                               +0.7                                                                                +1.4                                                                               +1.2                                                                               +2.1               50% Formic Acid                                                                              *    2600                                                                               *   -60 *   680 *   +19 *   -17 --  +6                  Synthetic     7300 5200                                                                               -14 -20 400 585  +2.4                                                                              +2.6                                                                               +2.3                                                                               *   --   +1.3               Perspiration                                                                   H.sub.2 O @ 70° C. (158° F.)                                                   3500 5200                                                                               -59 -20 450 680  +9.8                                                                              +19 +0.4                                                                               NA   +1.6                                                                              NA                  95% RH @ 70° C. (150° F.)                                                      1400 3700                                                                               -83 -43 170 620 -59 +8.7                                                                               --  --  --  --                  __________________________________________________________________________      *  sample dissolved                                                            NA  Data not available                                                   

    Physical Properties                                                                     Flame Retardant                                                                Polyether Base Material                                                                                 ASTM                                                  Typical                  Test                                                  Properties               Procedure                                    __________________________________________________________________________              UL Vertical 94 Flame Test                                                                               V O   --                                              Tensile, psi             4700  D412                                            100% Modulus, psi        850   --                                              300% Modulus, psi        1350  --                                              Elongation, %            570   --                                              Graves Tear, pli         370   D624                                            Crescent Tear, pli       460   D624                                            Hardness, A-C-D          87-58-41                                                                              D2240                                          Taber Abrasion, mgm loss, CS-17                                                                         6.2   --                                              wheel, 1000 gm, 1000 cycles                                                    Vicat B, °C.       94    D1525                                          Brittleness Temp         -70° C.                                                                       D746                                            Gehman RT Modulus        1250   D1053                                          T.sub.2                  -15° C.                                                                       --                                              T.sub.5                  -31° C.                                                                       --                                              T.sub.10                 -37° C.                                                                       --                                              T.sub.60                 -51° C.                                                                       --                                              T.sub.100                --    --                                              Freeze Point             -51° C.                                                                       --                                              Compression Set,         23%   D395                                            22 hours, RT                                                                   Compression Set,         66%   --                                              22 hours, 70° C.                                                        Specific Gravity         1.226 --                                     __________________________________________________________________________

The mattress core described above is thus surrounded by a fabric layer and a protective layer on four sides, two sides remaining uncovered, i.e. the short sides 4 and 5. Said sides are left uncovered in order to allow air to flow freely in and out of the mattress to retain its elasticity.

One application for the invention has been described above, that of a mattress. However, it should be obvious that the invention can also be used for cushions, pillows, car-seats, back-rests in furniture and for other applications where it is desired to avoid the sound effects mentioned above. 

What is claimed is:
 1. A method for producing an integrated elastic body of increased noise suppression comprising a predominantly open cell foam plastic core having upper and lower surfaces, longitudinal surfaces and transverse surfaces, and an outer non-permeable plastic layer overlying and secured to said core, comprising the steps of:(A) positioning an inner, noise suppressing fabric layer overlying said upper and lower surfaces and said longitudinal surfaces of said core; (B) adhering said fabric layer to said core over at least a portion of the surface of said core; (C) positioning said outer layer overlying said adhered inner layer and adjacent said upper and lower surfaces and said longitudinal surfaces of said core; and (D) adhering said outer layer to said inner layer and said core over at least a portion of the surface of said core, thereby forming said integrated elastic body.
 2. A method for producing an integrated elastic body according to claim 1, wherein said inner fabric layer is adhered to said core by the step of heating the surface of said core sufficiently to plasticize at least a portion of said core surface to adhere said fabric layer to said core by the plasticized portion of the core when is solidifies.
 3. A method for producing an integrated elastic body according to claim 1, wherein the step of adhering said outer plastic layer to said inner fabric layer and said core is accomplished by the step of heating the surface of said core sufficiently to plasticize at least a portion of said core surface to cause at least a portion of the plasticized core surface to penetrate said inner fabric layer and contact said outer layer to adhere said outer layer to said inner fabric layer and said core upon solidification of the plasticized portion of the core.
 4. A method for producing an integrated elastic body according to claim 1, wherein the step of adhering the inner noise suppressing fabric layer to said core is accomplished by the steps of providing an attachment strip coated on both sides with an adhesive; and interposing said adhesive coated strip between at least a portion of the surface of said core and said fabric layer to join at least a portion of the surface of said core and said fabric layer together.
 5. A method for producing an integrated elastic body according to claim 1, wherein the step of adhering said outer layer to said inner fabric layer and said core is accomplished by the steps of providing an attachment strip coated on both sides with an adhesive; and interposing said adhesive coated strip between said outer layer and said inner fabric layer to join said outer layer, said inner fabric layer, and at least a portion of the surface of said core together. 